Manufacturing Capabilities

US Drop Forge manufactures “Closed Die, Impression, Drop Forgings”. This process involves two dies, each containing a single impression or a series of multiple precision shapes cut into each die. Typically the bottom die is fixed in a set position and the upper die is raised some distance above the lower die. While the two dies are separated a controlled amount of material is heated to an exact temperature and positioned between the two die halves. When the two dies are brought together under extreme force, the material is deformed and forced to flow into the die impressions in a controlled manner. Any excess material present will flow through predetermined areas of the dies, called “Flash” and must be removed as a secondary operation.

Forgings at US Drop Forge can be manufactured by either of two different processes. “Drop Hammering” or “Pressing”.

Drop Hammer Forging – Forging on a Hammer is carried out in a series of die impressions using repeated blows of force until the two dies are brought into face to face contact with one another. The advantages of Hammer forging are many, but some of the key advantages are large forgings and difficult to forge alloy materials can be produced because of a Hammer’s ability to deliver multiple controlled blows to shapes, hence producing fine details which may be unobtainable with Press forging. Hammers also typically require less set up than a Press which in turn lends itself to be more versatile. Smaller production runs, ability to shape expensive exotic materials, intricate details, larger capacities are all distinct advantages of Drop Hammer forging.

Press Forging – Forging on a Press is carried out in a succession of die impressions much like Drop Hammer forging, however a Press has no ability to apply repeated blows to an impression and the two dies never come in face to face contact with each other. Repeated blows in any die impression on a Press serve no useful purpose. With Press forging, a controlled amount of force moves the upper die to a predetermined, fixed lower position which controls size and detail of the forging. Presses generally require a little more detailed set up than a Hammer which in turn lends Press forging to be less versatile.

Each forging process has applications and advantages in delivering precision “Closed Die, Impression, Drop Forgings” of the highest quality at minimal cost. It is because of US Drop Forge’s ability to route your forging(s) through the most cost effective forging process that keeps us a leader in our field. We invite your most demanding specifications and requirements.